HAND TOOL FOR APPLYING A FERRULE TO A CABLE

Abstract: A hand tool for crimping or swaging a ferrule (24) onto the free end of a safety cable (20) having a pre-swaged ferrule (22) installed at its other end (20a) and which has been threaded through a series of fasteners (10, 12, 14) to be tethered together, includes an elongate nose portion (46), relatively movable handles (26a, 28a), a knob type cable tensioner (200) including a tapered friction cable gripper (204) having a detent clutch device (210, 212) for limiting maximum tension applied to a safety cable by the knob tensioner, and a replaceable hardened cutter plate (250) at the distal cable cutoff area (46b) of the nose portion (46) of the tool.

Description: 'HAND TOOL FOR APPLYING A FERRULE TO A CABLE' BACKGROUND OF THE INVENTION The present invention relates to a hand tool for applying a ferrule to a safety cable passing through a plurality of threaded fasteners to prevent the unintentional unthreading of such fasteners of the type described in U.S. Patent No. 5,214,832 granted June 1, 1993. As described in Patent No. 5,214,832, in rotary machinery having close tolerances between rotating and stationary elements, such as turbines, it is imperative that all objects, no matter how small, be kept from contact with the rotating elements of the machinery. The presence of any foreign object could result in the catastrophic failure of the entire machine. Such machinery is inherently complex and requires many nuts, bolts, screws and other threaded fasteners to assemble all of its components. Since the operation of such machinery may involve very high rotating speeds, which may induce vibrations into the machine elements, it is necessary to provide some means for preventing the inadvertent unthreading of the numerous threaded fasteners. It is known to apply lock wires to threaded fasteners to prevent their inadvertent unthreading. Typically, the lock wire passes through a transverse hole in at least two threaded fasteners and is twisted back on itself in alternating clockwise and counterclockwise directions between the threaded fasteners. The process is duplicated between additional threaded fasteners until the entire threaded fastener pattern has been safety wired. Following die required stringing and twisting, the wire is cut and bent into a certain position. While the known lock wire technique has provided satisfactory results, it requires a very time consuming and laborious application process. Often the final result is unsatisfactory due to variations in the quantity and tautness of the twists, and the variations in the tension on the lock wire. It has been estimated that annual losses of approximately $10,000,000 are incurred just from re-working unacceptable lock wire assemblies. SUMMARY OF THE INVENTION The invention relates to a tool for crimping a motion stop ferrule on a safety cable extending through the bore of the ferrule while the cable is under tension and for cutting the free end of the cable from the ferrule after crimping, the tool including a body having at least one handle element connected thereto for manual manipulation, an elongate nose portion extending forwardly of the tool body and having a distal and a proximal end, said proximal end connected to the tool body; and a ferrule crimping punch driving element extending axially along the nose portion and operatively connected to the handle element for reciprocating motion upon manipulation of the handle element. The distal end of the nose portion includes a ferrule receiving opening extending partially therethrough and transversely of the nose portion distal end. A crimping punch is disposed at the distal end area of the nose portion and is operatively connected to the punch driving element for reciprocal movement axially along the nose portion. T e crimping punch includes a distal end extending axially into the ferrule receiving opening upon outward reciprocal movement to a sufficient extent to cause crimping of a ferrule that is located in the opening. A safety cable tension device is operatively associated with the tool body and is arranged to be engageable by a safety cable extending from the distal end of the nose portion to apply tension force to a cable upon actuation thereof. The ferrule receiving opening is elongate in the axial direction of the nose portion and has a length greater than the diameter of a ferrule to be crimped by the tool. The opening also has a proximal end disposed towards the crimping punch and a longitudinally opposed distal end. The opening includes a transversely extending sidewall at the distal end and the crimping punch cooperates with the sidewall at the distal end during crimping of a ferrule that is placed in the opening. The distal end of the nose portion includes a safety cable receiving aperture having at least one dimension extending transversely across the aperture that is smaller along at least one dimension than the diameter of a ferrule to be crimped by the tool. The aperture extends transversely of the nose portion in the same direction as the ferrule receiving opening and intersects the bottom of the ferrule receiving opening where the safety cable receiving bore of a ferrule is disposed before crimping. The aperture is located closer to the distal end of the crimping punch than the distal end of the ferrule receiving opening when the punch distal end is disposed at a position adjacent a ferrule located in the opening so that upon extension of the crimping punch and with the ferrule disposed in the ferrule receiving opening so that its bore is aligned with the cable receiving aperture and its one end is resting against the bottom of the opening with a safety cable extending through the bore, a ferrule will be driven axially relative to the cable receiving aperture against the transverse extending sidewall to be thereby crimped. The axial movement of the ferrule will cause a safety cable extending through the ferrule bore and cable receiving aperture to be sheared between the end of the ferrule located against the bottom wall of the opening and the bottom wall of the opening itself. The bottom wall of the opening includes a hardened cutter element that may be replaceable and lies adjacent the cable receiving aperture. The cutter element has a cutter edge adjacent the cable receiving aperture and is adapted to engage and shear a cable when a ferrule through which the cable extends is axially displaced by the punch during crimping. The invention also comprises apparatus of the type above described, with or without the cutter element, wherein the safety cable tension device includes a rotary knob operatively associated with the tool body and connected to a tapered cable friction gripper by a detent clutch mechanism arranged to disconnect the knob from the tapered cable friction gripper when tension in a safety cable gripped by the friction gripper exceeds a threshold limit. A suitable device is also included for preventing rotation of the knob in a cable unwinding direction. Additional features of the invention will be evident from a reading of die detailed description provided below taken in conjunction with the appended drawings. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a plan view of a safety cable applied according to the known techniques. Figure 2 is a plan view of a safety cable applied using the apparatus according to the present invention. Figure 3 is a top plan view of the hand tool according to the present invention. Figure 4 is a longitudinal cross-sectional view taken along line IV-IV in Figure 3. Figures 5A-5C are schematic illustrations of the use of a ferrule holding member to position the ferrule while threading the safety cable through the ferrule and the hand tool. Figures 6A and 6B are side views of the ferrule holding member illustrating the storage and withdrawal of a ferrule from the ferrule holding device. Figure 7 is a partial, top, cross-sectional view illustrating the ferrule installed on the safety cable and inserted into the tool ready to be crimped. Figure 8 is a top, exploded view of the tension mechanism according to the prevent invention. Figure 9 is a rear view of the clutch plate viewed in the direction of arrow IX in Figure 8. Figure 10 is a partial, cross-sectional view taken along line X-X in Figure 9. Figure 11 is a front view of the tension member viewed in the direction of arrow XI in Figure 8. Figure 12 is a front view of the tension adjusting screw viewed in the direction of arrow XII in Figure 8. Figure 13 is a cross-sectional view of the ratchet mechanism utilized in the present invention. Figures 14A-14C are schematic illustrations of the sequential movement of the ratchet mechanism illustrating the positions of the ratchet pawl. Figure 15 shows an alternate embodiment of the invention showing a different tension mechanism. Figure 16 shows an alternate embodiment of d e ferrule crimping and safety cable cutting portion of the tool according to the invention. Figure 17 shows an exploded view of the tension mechanism shown in Figure 15. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT As described in U.S. Patent No. 5,214,832, a lock wire 18 applied in accordance with the prior art is illustrated in Fig. 1 wherein threaded fasteners 10, 12 and 14 are engaged with a portion 16 of a rotating apparatus (not otherwise shown). The lock wire 18 comprises two wire strands 18a and 18b twisted together at one end are separated such that strand 18a passes through a transverse opening in fastener 10 while strand 18b passes around the exterior of the fastener 10. The strands are twisted togedier on the opposite side of fastener 10 and, again, one strand passes through a transverse opening formed in fastener 12 while the other strand passes around fastener 12. The lock wire 18 continues until the last fastener, in this particular instance fastener 14, whereupon one strand passes through a transverse opening in the fastener, while the other strand passes around die exterior of the fastener. The strands are twisted togedier on the opposite side of the fastener 14. Fig. 2 illustrates a safety cable system applied using the apparatus described in U.S. Patent No. 5,214.832. Threaded fasteners 10, 12 and 14 are once again engaged widi the machinery portion 16. Safety cable 20 comprises a ulti strand cable having a motion stop ferrule 22 affixed to end 20a. Safety cable 20 passes tiirough transverse openings formed in the threaded fasteners 10, 12 and 14 until ferrule 22 bears against one side of fastener 10. At this point, ferrule 24 is inserted over die end of cable 20 against the side of fastener 14, a tension is applied to the safety cable 20 and the ferrule 24 is crimped onto the safety cable such that it bears against a side of the fastener 14 thereby securing the cable to the series of fasteners through which it is threaded. Safety cable 20 is then automatically trimmed. The pre-determined is tension is maintained in safety cable 20 by the contact of ferrules 22 and 24 with the sides of the threaded fasteners 10 and 14, respectively. In Figures 3 and 4, die hand crimping tool comprises a pair of handle members 26 and 28 pivotally attached togedier via pivot pin 30 so as to pivot about the longitudinal axis of the pivot pin 30 toward and away from each other as illustrated by arrows 31. The handle members 26 and 28 may have cushioned or coated hand gripping areas 26a and 28a, respectively, and may have bifurcated front portions with generally parallel extending portions illustrated at 26b and 26c in Figure 3. It is to be understood that handle 28 may have a similar bifurcated construction, but with the bifurcated members located closer togedier such that the front portions of handle 28a may fit between portions 26b and 26c near die pivot pin 30. Link member 32 has a first end pivotally attached to handle member 26 by a pivot pin 34, whose axis may extend generally parallel to me axis of pivot pin 30. The opposite end of link member 32 is pivotally attached to a fixed body member 36 by a pivot pin 38. In similar fashion, link member 40 has a first end attached to handle member 28 via pivot pin 42 and a second end pivotally attached to body member 36 by pivot pin 44. Again, the axis of pivot pin 42 may extend parallel to that of pivot pin 30. An elongated nose portion 46 of body 36 has a proximal end portion 46a fixedly attached to body member 36, such as by brazing or die like. Elongated nose portion 46 also has a distal end portion 46b which includes a ferrule receiving opening 48, at least a portion of which has a generally triangular elongate configuration as illustrated in Figure 4, the opening including a proximal end 48a adjacent punch driving member 50 and an opposed distal end 48b. Elongated nose portion 46 has a longitudinally extending, central opening which slidably accommodates crimping punch driving member 50. Driving member 50 has an end 50a attached to die handle members 26 and 28 by pivot pin 30. As will be hereinafter explained in more detail, d e driving member 50 is movable between a retracted position at which a crimping punch distal end 50b does not extend significantly into opening 48 and a full crimping position at which punch 50b extends into die opening 48 through a proximal sidewall thereof so as to bear against a ferrule in the opening 48 so as to crimp the ferrule onto a safety cable extending through die ferrule. As will be described below, a cable receiving aperture 70 extends into the bottom of opening 48. In order to use die hand tool dius far described, die safety cable must first be threaded through a ferrule as well as the aperture 70; a tension must be applied to die safety cable to a predetermined value; and the ferrule must be permanentiy crimped onto die safety cable. The first portion of the operational procedure may be carried out widi the assistance of a ferrule holding member illustrated generally at 52 in Figures 5A-5C, 6A and 6B. The ferrule holding member 52 may have a magazine portion 54 defining a storage chamber 56 adapted to accommodate a plurality of ferrules 24. In Figures 5A and 6A four such ferrules 24a, 24b, 24c and 24d are illustrated, but it is to be understood diat any number of such ferrules may be stored in die storage chamber 56. Ferrule holding member 52 also has an insertion chamber 58 which is defined by edge portions 58a and 58b. As can be seen in Figures 5A and 6A, spring 64 bears against a portion of the magazine 54 and die uppermost ferrule in the magazine (in this instance ferrule 24d) so as to urge the stack of ferrules from the storage chamber 56 into the insertion chamber 58. Resilient lip members 60 and 62 extend from the ferrule holding member 52 and are located so as to frictionally engage surfaces 46c and 46d formed on opposite sides of nose portion 46. When resilient lip members 60 and 62 have removably attached die ferrule holding member 52 to the nose portion 46, the insertion chamber 58 is in alignment with opening 48. Ferrule holding member 52 may also define collar extensions 66 and 68 extending from opposite sides. Each of these extensions define an opening which is in alignment with the opening of the ferrule 24a located in the insertion chamber 58. The distal end of the opening extending through extension 66 may be beveled so as to have a generally conical shape to facilitate die threading of die end of die safety cable into and through the ferrule holding member 52. As can be seen in Figure 5A, the end of die safety cable 20 is placed through the opening in the extension 66 which automatically directs die cable dirough the opening in the ferrule 24a and out dirough the opening in the extension 68. The end of cable 20 is then inserted dirough 48 in the elongated body 46 as well as a smaller, generally cylindrical cable receiving aperture 70 which communicates with opening 48 at the opposite side of nose portion 46, as illustrated in Figure 7. Cable receiving aperture 70 intersects the bottom of opening 48 closer to the proximal end 48a of ferrule receiving opening 48 than the distal end 48b of die opening as illustrated in Figure 7 such that, when a ferrule 24a is placed in the opening 48, the central opening through die ferrule 24a will be aligned widi die aperture 70 to permit threading of the cable 20 through the ferrule 24a and aperture 70. Of course, die diameter of the aperture 70 essentially corresponds widi the diameter of cable 20 so mat, during crimping, the free end of cable 20 extending beyond ferrule 24a will be severed from that portion of the cable extending dirough the ferrule 24a, all of which will be described in more detail below. Once the desired amount of safety cable 20 has been pulled through the threaded member 14, die ferrule 24a and die nose portion 46, the ferrule holding member 52 is moved in me direction of arrow 72 in Figure 5B so as to disengage die ferrule holding member 52 from the elongated body 46. As can be seen in Figure 6A, ferrule holding member 52 has reduced thickness wall portions 74 and 76 located generally on opposite sides of die insertion chamber 58. These reduced thickness wall sections 74 and 76 enable die lower portion of the ferrule holding member 52 separated by slit 59 and located on eidier side of die insertion chamber to pivot outwardly, as illustrated in Figure 6B, when the ferrule holding member is urged upwardly in die direction of arrow 78 as illustrated in Figure 5C. Movement in the direction of arrow 78 allows the ferrule 24a in the insertion chamber 58, which has been threaded onto safety cable 20, to pass outwardly from die ferrule holding member 52. Once ferrule 24a has cleared die edge portions 58a and 58b, die natural resiliency of the ferrule holding member 52 returns its lower portion to the configuration illustrated in Figure 6A to prevent odier ferrules from being ejected. Spring 64 then urges the stack of ferrules downwardly such tiiat ferrule 24b is now located in die insertion chamber. Following the removal of the ferrule holding member 52, nose portion 46 is moved in die direction of arrow 80, as illustrated in Figure 5C, to insert the ferrule 24a into the opening 48. as illustrated in Figure 7. At this point, it is necessary to apply a predetermined tension to the safety cable 20 before permanently attaching ferrule 24a to the cable by crimping. This is accomplished by attaching the end of safety cable 20 to a tensioning device, generally indicated at 82 in Figure 3 and 8. The tensioning mechanism is illustrated in Figures 8-12. The tensioning mechanism according to die present invention comprises a one-way rotation mechanism 84, which may be any known, commercially available device. Tension member 86 is inserted through one- way rotation device 84 such that its headed portion 86a is located on one side of die mechanism 84, while a safety cable gripping portion 86b extends out the opposite side. End 86b may define a slot 88 having an enlarged, inner portion 88a so that the end of d e safety cable 20 may be inserted into die slot 88 and displaced from alignment with the slot 88 in the enlarged portion 88a. Notch 89 may accommodate a C-clip (not shown) to retain the tension member 86 in the one-way rotation mechanism 84. Tension member 86 also defines a longitudinally extending central opening, which is internally threaded. Face 90 of head portion 86a has mounted diereon at least one protrusion 92 extending therefrom. The protrusions 92 may be ball members rotatably affixed to die tension member, or members fixedly attached to and extending from the face 90. Although four such protrusions are shown (see Figure 11) it is to be understood tiiat more or less may be utilized in any application of the tool. Clutch plate 94 is fixedly attached to a recessed portion of winding or control knob member 96 via any known means, such as threaded fasteners, or die like. Face 98 of clutch plate 94, as illustrated in Figures 9 and 10, defines at least one indentation 100 having an inclined ramp surface 102. The indentations 100 are dimensioned so as to be engaged by die protuberances 92. The number of indentations is equal to die number of protuberances. A locking pin 104, whose functions will be more completely described hereinafter, is attached between die control knob 96 and the clutch plate 94. As can be seen in Figure 8, locking pin 104 has an enlarged portion 104a which is slidably contacted by lip 96a of control knob 96 as well as lip 94a defined by the clutch plate 94. The engagement between these members is such that rotation of the control knob 96 and, consequendy, the clutch plate 94 about axis 106 will not cause rotation of the locking pin 104 about the axis, but any axial movement of the control knob 96 along its rotational axis 106 will cause pin 104 to also move axially in this direction. Tension adjusting screw 108 has a headed portion 108a and a threaded shank portion 108b which extends dirough the control knob 96, the clutch plate 94 and is threadingly engaged with the central opening defined by tension member 86. One or more wave spring washers 110 may be operatively interposed between the headed portion 108a of the tension adjusting screw 108 and d e control knob 96. The face 108c of the tension screw 108 defines a slot 108d to facilitate rotation of the tension adjusting screw by a screwdriver or die like. Set screw 109 may be threaded into die opposite end of die central opening in the tension member 86 so as to bear against an end of shank 108b of tension adjusting screw 108. This locks tension adjusting screw 108 in its desired location and prevents inadvertent rotation of the tension adjusting screw. The tension mechanism works as follows. After the end of safety cable 20 has been inserted into slot 88 and enlarged end portion 88a, the control knob 96 is manually rotated about axis 106. Due to die presence of one-way rotation mechanism 84, tension member 86 and, consequently, the control knob 96 will rotate only in one direction. The biasing force of wave spring washers 110 urges the control knob 96 as well as the clutch plate 94 towards the tension member 86 along axis 106 such that the protrusions 92 drivingly engage the indentations 100. Thus, rotation of control knob causes rotation of the tension member 86 dirough d e clutch plate 94. Such rotation causes a safety cable 20 inserted dirough a ferrule while restrained against longitudinal movement to be wound upon the end 86b of the tension member 86, such winding motion increasing the tension within the safety cable 20. Once this tension reaches a predetermined level, die rotative force exerted on the tension member 86 by the engagement of the protrusions 92 with die indentations 100 becomes less than the restrictive force exerted on die tension member 86 by the safety cable 20. This prevents tension member 86 from rotating and causes the protrusions 92 to slide along inclined ramp surfaces 102 as control knob 96 is rotated. This causes axial movement of the control knob 96 along axis 106 in a direction away from die tension member 86. Once the protrusions 92 are out of engagement with the indentations 100, no further rotation of tension member 86 can take place through the control knob 96. Rotation of the tension member 86 in die opposite direction is prevented by one-way rotation mechanism 84. The level of tension at which the protrusions 92 slide along the inclined ramp surfaces 102 may be adjusted by rotating the tension adjusting screw 108. Rotation in one direction will increase the biasing force toward die right (as shown in Figure 8) on die control knob 96 urging it toward tension member 86 and diereby applying a greater tension to the safety cable 20 before the disengagement of the protrusions 92 from the indentations 100. Similarly, rotation of die tension adjusting screw 108 in the opposite direction will lessen die tension applied to die safety cable 20 before such disengagement takes place. Once the proper tension has been applied to d e safety cable 20, die ferrule 24a may be crimped onto d e safety cable. This is achieved by manually urging handle members 26 and 28 towards each odier. As illustrated in Figure 4, such movement of the handle members 26 and 28 will cause pivot pins 34 and 42 to move around die axis of pivot pin 30. Such movement causes relative movement between the nose portion 46 and die crimping punch driver 50 which is attached to the pivot pin 30. As best seen in Figure 7, moving die handles 26 and 28 towards each other will cause drive 50 to move toward die left with respect to nose portion 46. The extending motion of die crimp punch 50b, along with the generally triangular configuration of opening 48 deforms die ferrule 24a so as to be crimped and permanendy attached to safety cable 20. Moreover, die relative movement between the elongated body 46 and d e ferrule 24a causes a shearing action on the safety cable 20 between the inner edge of aperture 70 and die adjacent lower edge of die ferrule 24a. The edges are moving in opposite relative directions so as to exert a shear action on die safety cable 24, which shear action severs the free end of d e cable as the ferrule 24a is being crimped. In order to prevent die movement of handle members 26 and 28 away from each odier before die ferrule 24a has been permanendy attached to die safety cable 20, ratchet mechanism 112 is provided. As best seen in Figures 4 and 13 ratchet mechanism 112 comprises a ratchet body 114 attached to handle member 26 via pivot pin 116. It also comprises a support body 118 attached to handle member 28 via pivot pin 120. Support body 118 defines a laterally extending opening 122 in which is mounted die one-way rotation mechanism 84 of the tensioning device. Ratchet member 124 is attached to die support body 118 via threads 126. Ratchet member 124 also extends dirough the ratchet body 114 and defines a plurality of ratchet teeth 128 extending over a length 1 of the ratchet member 124. Ratchet member 124 also defines ratchet grooves 130 located at eidier end of the ratchet teeth 128. The depth of ratchet teeth 130 is greater d an that of ratchet teeth 128 as illustrated in Figure 13. Pawl 132 is pivotally attached ratchet body 114 via pivot pin 134. Resilient biasing members 136a and 136b are located on opposite sides of pawl 132 and exert a biasing force thereon urging it to the central position illustrated in Figure 13. Compression spring 138 is operatively interposed between die ratchet body 114 and support body 118 so as to normally urge these elements apart. The operation of the ratchet mechanism can be seen from Figures 14A-14C. Movement of handle members 26 and 28 towards each other will cause ratchet body 114 and support body 118 to also move towards each odier. Thus, ratchet body 114 moves in d e direction of arrow 138 in Figure 14A relative to ratchet member 124a. Pawl 132 defines an engagement edge 140 which, when die ratchet body 114 is displaced towards support body 118, engages ratchet teedi 128. The movement of ratchet body 114 will cause pawl 132 to pivot about pivot pin 134 so as to compress resilient biasing member 136a. This compression will increase the force urging die pawl 132 toward its central position illustrated in Figure 13. However, the depdi of the ratchet teedi 128 is insufficient to allow the pawl 132 to return to this position. Thus, once die engagement edge 140 engages ratchet teedi 128, it is impossible for ratchet body 114 to move in any direction odier than that indicated by arrow 138 in Figure 14a. This prevents the handles 26 and 28 from being moved apart as long as pawl 132 is engaged widi ratchet teeth 138 to prevent partial crimping of a ferrule. Once die handles 26 and 28 have been moved towards each odier sufficiently for the crimping punch 50 to have fully crimped die ferrule 24a onto die safety wire 20, die ratchet body 14 and die support body 118 will be in die positions illustrated in Figure 14B. In this position, engagement edge 140 of pawl 132 enters d e lower ratchet groove 130 which has a depdi sufficient to allow the pawl 132 to be returned to its central position due to die biasing force of resilient biasing member 136a. Once the engagement edge 140 enters die groove or ratchet tooth 130, ratchet 114 and support body 118 may move away from each other, as illustrated in Figure 14C. Movement of ratchet body 114 relative to support body 118 in die direction of arrow 142 will bring engagement edge 140 once again into contact with ratchet teeth 128. The depth of die ratchet teedi 128 will cause d e pawl 132 to pivot about pivot pin 134 and compress resilient biasing member 136b. This depdi, however, is insufficient to allow the pawl 132 to return to its center position. This prevents movement of ratchet body 114 in any direction except diat indicated by arrow 142. Once ratchet body 114 reaches die position illustrated in Figure 13, the upper ratchet groove 130 will enable the pawl 132 to be returned to its center position by resilient biasing members 136a and 136b. The tool thus far described also includes a locking device for positively preventing die movement of handles 26 and 28 towards each odier until die predetermined tension has been established in safety cable 20. This is achieved by locking member 144 which may be threaded onto ratchet body 114 and slidably extend dirough support body 118. Locking member 144 defines a circumferential locking recess 146 which, when the handles 26 and 28 are in their fully opened position and ratchet body 114 is in die position illustrated in Figure 13 (wherein the engagement edge 140 is located in ratchet groove 130) die locking recess 146 is in alignment with transverse opening 148 defined by support member 118. When the tension mechanism 82 is assembled and one-way rotation mechanism 84 is mounted in opening 122 dirough the support body 118, locking pin 104 attached to die control knob 96 extends into opening 148. The length of locking pin 104 is such that, as long as the control knob 96 is in driving engagement widi die tension member 86 (indentations 100 are in driving engagement with protrusions 92), pin 104 extends through die opening 148 and into the locking recess 146. This prevents any movement of locking member 144 along its longitudinal axis, thereby preventing handles 26 and 28 from being moved toward each other. As previously noted, once die proper tension in cable is achieved, d e action of protrusions 92 moving along the inclined ramp surfaces 102 will cause control knob 96 and clutch plate 94 to move axially along die rotational axis 106. This axial movement withdraws pin 104 from engagement with die locking recess 146, thereby enabling the ratchet body and support body to be moved towards each odier along with handle members 26 and 28. An improved tensioning device and cable cut off system according to diis invention are shown in Figures 15 and 17, where similar elements of the tool illustrated in Figures 1- 14(c) are identified by corresponding reference numerals. In this arrangement, the tensioning device 200 includes a manual rotary knob 202 about which safety cable 20 is wrapped by the operator of the tool until a section of die cable lies widiin a tapered groove 204 and is frictionally engaged between the knob 202 and a back plate 206 (see Figure 17). Spring- biased ball elements 208 retain the free end of safety cable 20 between the knob 202 and plate 206 during preliminary rotation of the knob 202. Upon continued rotation of knob 202, cable 20 is securely engaged between die underside of knob 202 and plate 206 in groove 204 so that it is progressively wrapped about die axis of rotation of knob 202 to thereby tension the safety cable 20 in the direction of the tool handles 26(a), 28(a). As shown in Figure 17, knob 202 actually comprises an assembly of an outer knob element 202 and an inner knob 202(a) that is connected to die outer knob element 202 through a spring clutch detent 210 diat cooperates widi serrations 212 within die inner peripheral surface of knob element 202. Thus, knob 202 drives inner knob element 202(a) through die spring detent 210 until tension in safety cable 20 lodged in the tapered groove 204 creates sufficient resistance to overcome the spring clutch detent 210, whereupon continued rotation of knob 202 will cause the serrations 212 to slip over the spring 210 and effectively disconnect d e knob 202 from continued driving relationship widi inner knob element 202(a) so that such knob rotation does not increase tension in die cable 20. Reverse rotation of knob 202 is prevented at all times by means of a one-way clutch 212 widiin support body 118 which is coupled to die knob 202 by means of shaft 214 which includes a square drive pin 216 coupled to square drive opening 218 in knob 202. Shaft 214 may be round so that inner knob 202(a) and plate 206 freely rotate about the shaft 214. Knob 202, however, due to the coupling relationship between die square drive 216 and die square opening 218, is positively coupled for rotation to shaft 214. One-way clutch 212 may be of any known variety and is arranged to bodi support die shaft 214 and to permit shaft 214 to rotate only in a single direction. Shaft 214 is illustrated as coupled to a support plate 220 which may include a friction surface 222 against which the underside of backplate 206 rests when the tension device is fully assembled. Assembly of the tension device involves sliding plate 206 and inner knob 202(a) over shaft 214 so that the underside of plate 206 rests against friction surface 222. Knob 202 is then slipped over die square drive 216 and dien flat and spring washers 224, 226 are placed within recess 228 in knob 202. Threaded retainer screw 230 and cover plate 232 are then placed over die washers 224. 226, with screw 230 engaging die direads in opening 234 in shaft 214. Operation of the tensioning mechanism 200 merely involves wrapping a free end of safety cable 20 over die knob 202 so that the wire is engaged in die tapered groove 204, widi die free end sliding past one of die spring biased ball elements 208. A plurality of spring biased ball elements 208 may be spaced circumferentially around die inner knob 202(a) to provide ready access for securing a free end of a safety cable during each tensioning operation. Rotation of knob 202 in a cable winding direction is then carried out until knob 202 begins to slip relative to inner knob 202(a) whereupon the handles may be actuated to crimp ferrule 22(a) on safety cable 20, as previously described. In accordance with this embodiment of me invention, die handles 26(a), 28(a) may be activated to cause crimping of ferrules 24(a) independendy of the degree of tension in safety cable 20. More specifically, in accordance widi die embodiment of Figures 15 and 17, locking pin 14 illustrated in Figure 8 and locking member 144 illustrated in Figure 13 are omitted. The ferrule crimping portion of the tool according to diis invention is illustrated in Figure 16. In accordance widi diis embodiment, a replaceable cutting plate 250 preferably made of hardened metal such as tool steel is provided at die bottom of opening 48 to improve die wear characteristics of the crimping and cutting portion of the tool. The plate 250 provides a sharpened edge against which die cable 20 is urged by ferrule 24(a) during crimping to diereby cause shearing of the cable 20 adjacent die lower surface of the ferrule 24(a). The plate 250 may be constructed so as to be replaceable to increase the service life of the tool. In accordance widi die embodiment of Figure 16, the crimping punch 51a includes a flattened bottom section 51b that slides over plate 250 when the punch is extended towards it full crimping position towards the distal wall 48b of opening 48 to assist in die shearing action used to cut the free end of cable 20 away from die ferrule during crimping. The crimping punch 51a, of course, is also located so as to be closely adjacent die bottom of opening 48 next to cutting plate 250 to maximize the shearing force used for cutting the free end of cable 20 away from the remainder of the cable. To ensure d at the ferrule 24(a) is disposed contiguous widi die cutting plate 250 during crimping, die depdi of opening 48 is selected such that d e length of a ferrule 24(a) to be crimped by die tool is always slighdy longer than the depdi of die opening 48 to ensure that the ferrule, which is disposed between fastener 14 and plate 250 is pressed against die plate 250 when the distal end portion 46b of die body member 46 is brought up against the fastener 14 in preparation for crimping of die ferrule and cutting of die cable. It is be to be noted tiiat opening 48 is generally triangular and elongate as shown in Figure 4, whereby a ferrule disposed in die opening is lodged at die wider end of die opening and gendy rests against the two sides of die narrow end of die opening before crimping. Crimping forces the ferrule to be wedged against the narrow end of die opening 48 by the punch 50b widi sufficient relative movement as described above to cause shearing of cable 20. The foregoing description is provided for illustrative purposes only and should not rued as in any way limiting d is invention, die scope of which is defined solely by nded claims.

Claims: Claims: 1. Apparatus for crimping a motion stop ferrule to a wire type safety cable extending dirough the bore of die ferrule while under tension and for cutting the free end of die cable from die ferrule upon crimping comprising: a tool body having at least one handle element connected thereto for manual manipulation; an elongate nose portion extending forwardly of the tool body and having a distal end and a proximal end, said proximal end connected to die tool body; a ferrule crimping punch driving element extending axially along the nose portion and operatively connected to die handle element for reciprocating motion upon manipulation of the handle element; said distal end of said nose portion including a ferrule receiving opening extending partially therethrough and transversely of the nose portion distal end; a crimping punch disposed at the distal end area of said nose portion, operatively connected to die punch driving element for reciprocal movement axially along the nose portion, and including a distal end extending axially into said opening upon outward reciprocal movement to a sufficient extent to cause crimping of a ferrule located in said opening; a safety cable tension device operatively associated wid the tool body and arranged to be engageable by a safety cable extending from die distal end of said nose portion to apply tension force to such cable upon actuation thereof; said ferrule receiving opening being elongate in die axial direction of said nose portion and having a lengtii greater tiian die diameter of a ferrule to be crimped by die tool, said opening having a proximal end disposed toward the crimping punch and a longitudinally opposed distal end; said opening including a transversely extending sidewall at said opening distal end, said crimping punch cooperating widi said sidewall during crimping of a ferrule disposed in said opening; a safety cable receiving aperture having at least one dimension extending transversely across die aperture that is smaller man the diameter of a ferrule to be crimped by die tool, said aperture extending transversely of said nose portion in die same direction as said ferrule receiving opening and intersecting the bottom of said ferrule receiving opening where the safety cable receiving bore of a ferrule is disposed before crimping, said aperture being located closer to said distal end of said crimping punch than said distal end of said ferrule receiving opening when the punch distal end is disposed at a position adjacent a ferrule located in. said ferrule receiving opening so that, upon extension of die crimping punch and widi a ferrule disposed in the ferrule receiving opening so that its bore is aligned widi the cable receiving aperture and its one end is resting against die bottom of the opening widi a safety cable extending through the bore, a ferrule will be driven axially relative to the cable receiving aperture against said transversely extending sidewall to be thereby crimped, and said axial movement will cause a safety cable extending through the ferrule bore and cable receiving aperture to be sheared between die end of the ferrule located against the bottom wall of the opening and die bottom wall of the opening; and wherein the bottom wall of said opening comprises a hardened cutter element adjacent said cable receiving aperture, said cutter element including a cutter edge adjacent said cable receiving aperture and adapted to engage and shear a cable when a ferrule through which die cable extends is axially displaced by die punch during crimping. 2. Apparatus as claimed in claim 1, wherein said cutter is removably connected to die nose portion of die tool. 3. Apparatus as claimed in claim 1 or 2, wherein said punch includes a flat lower surface extendible over and contiguous with said cutter edge when said punch extends towards a full crimping position; said punch, when extended to its full crimping position, overlying said cable receiving aperture, whereby said lower surface assists shearing of a cable extending adjacent said cutter edge. 4. Apparatus as claimed in claim 3, wherein said lower flat surface of said punch is arranged to normally retain said cutter in said ferrule receiving opening. 5. Apparatus as claimed in claim 1, wherein die depdi of said ferrule receiving opening is selected so diat it is less than die total height of a ferrule to be crimped. 6. Apparatus as claimed in any of die preceding claims, wherein said safety cable tension device comprises a rotary knob operatively associated widi the tool body and connected to a tapered cable friction gripper by a detent clutch mechanism arranged to disconnect the knob from the tapered cable friction gripper when tension in a cable gripped by die friction gripper exceeds a direshold limit, a means for preventing rotation of die knob in a cable unwinding direction. 7. Apparatus as claimed in claim 6, including at least one cable engaging detent for releasably engaging a free end of a cable inserted in die friction gripper to cause die free end to be carried and wound about die gripper upon rotation of the knob in a winding direction. 8. Apparatus as claimed in claim 6 or 7, including a partial crimping prevention device associated widi said handle element and arranged to prevent retraction of the ferrule crimping punch driving element away from die ferrule receiving opening once die driving element has been actuated by die handle element towards an extended position until d e crimping punch has been extended to a full crimping position. 9. Apparatus for crimping a motion stop ferrule to a wire type safety cable extending dirough die bore of die ferrule while under tension comprising: a tool body having at least one handle element connected tiiereto for manual manipulation; an elongate nose portion extending forwardly of the tool body and having a distal end and a proximal end, said proximal end connected to the tool body; a ferrule crimping punch driving element extending axially along the nose portion and operatively connected to die handle element for reciprocating motion upon manipulation of the handle element; said distal end of said nose portion including a ferrule receiving opening extending partially therethrough and transversely of the nose portion distal end; a crimping punch disposed at the distal end area of said nose portion, operatively connected to die punch driving element for reciprocal movement axially along the nose portion, and extending axially into said opening upon outward reciprocal movement to a sufficient extent to cause crimping of a ferrule located in said opening; a safety cable tension device operatively associated widi die tool body and arranged to be engageable by a safety cable extending from die distal end of said nose portion to apply tension force to such cable upon actuation thereof; said safety cable tension device comprising a rotary knob operatively associated with the tool body and connected to a tapered cable friction gripper by a detent clutch mechanism arranged to disconnect die knob from die tapered cable friction gripper when tension in a cable gripped by die friction gripper exceeds a direshold limit, and means for preventing rotation of the knob in a cable unwinding direction. 10. Apparatus as claimed in claim 6 or 9, including at least one cable engaging detent for releasably engaging a free end of a cable inserted in die friction gripper to cause the free end to be carried and wound about die gripper upon rotation of d e knob in a winding direction. 11. Apparatus as claimed in claims 6, 9 or 10, including a partial crimping preventing device associated with said handle element and arranged to prevent retraction of the ferrule crimping punch driving element away from die ferrule receiving opening once the driving element has been actuated by die handle element towards an extended position until die crimping punch has been extended to a full crimping position.

Inventors: KOEHLER ROBERT H, KOEHLER WILLIAM E, KOEHLER, ROBERT, H., KOEHLER, WILLIAM, E.
Applicants: BERGEN CABLE TECH INC, BERGEN CABLE TECHNOLOGIES, INC.
Application year: 1994
Main classification: B23P19
IPC codes: B25B23, B25B27